SA516371052B1 - A Method for Molding Plastic Parts by an Injection Molding Machine - Google Patents

Abstract

The steps of the injection molding method comprises (a) fitting the injection molding machine with an injection mold (1) defining one or more molding cavities (8a,8b,8c,8d), at least one of the mold plates 2,3) are provided with one or more channels (11,14) for circulation of a tempering medium, (b) providing a feed of plastic material having a first temperature within the processing window, (c) heating molding cavities (8a,8b,8c,8d) to a second temperature within the processing window circulating through the one or more channels (11,14) a first tempering medium having a third temperature, (d) injecting plastic material having the first temperature into the closed heated mold (2,3) to fill the molding cavities (8a,8b,8c,8d), (e) cooling at the molding cavities (8a,8b,8c,8d) of the filled closed injection mold (2,3) to a fourth temperature below the first temperature until at least partly solidification of the molded plastic parts by circulating through the one or more channels (11,14)

Description

A method for injecting plastic parts with an injection molding machine

A Method for Molding Plastic Parts by an Injection Molding Machine Full Description BACKGROUND The present invention relates to a method for injection molding plastic parts by means of an injection molding machine “especially a method for molding polymeric parts Thermoplastic injection molding of any kind and into any shape. A conventional injection molding machine for medium and large-scale manufacturing of plastic parts comprises a granular plastic feedstock injection from which the plastic feedstock material is piped to an injection gate of an injection mold for example using a screw conveyor. or piston. On its way to the injection gate, the plastic feedstock passes through a heating section until it melts and can be injected under high pressure into the injection mold. 10 Molten plastic is injected into a shot; It represents the volume required to fill the molding cavity “cavity” to compensate for shrinkage; and provide a liner to transfer pressure from the conveyor system to the molding cavity. when enough material has collected at the injection gate; Molten plastic is forced at high pressure and a high flow velocity along overcast sleeves/sleeves into one or more injection mold cavities. The injection recesses in this injection mold are defined between the injection mold plate and the mold plate 5 Pronunciation against a close seam defines one or more molding recesses and defines the injected volume of molten plastic. The injection mold, along with its molding recesses, shall be at a temperature lower than the solidification temperature of the injected plastic material. Pressure is maintained until the ingot hardens at the injection gate such that no other material A can enter one or more of the bores. Then the screw or hydraulic piston “FAM” of the JBL system exchanges the same distance as the screw or hydraulic piston 0 moves forward when filling one or more molding cavities” and obtains the plasticizing material for the next cycle Lay the material cools Plasticizing inside the mold and hardens until Se is injected into a fixed dla

Dimensions. This conventional injection molding machine is known by example from International Patent Application No. 2012 [055872]. Solidification can be induced in some applications by cooling lines in the mold. refrigerant circulates; Such as water or oil in the cooling lines to achieve proper cooling. In these embodiments the mold is kept cold while the shot is being injected until the sale of the molten plastic feed begins to solidify at about the same time as the beginning of filling one or more of the molding cavities where one or more molding cavities are identical or different. Once the desired cooling temperature is reached; The mold is opened and the hall pins (parts) harden from the injection mold; And the process is repeated. International Patent Application No. 11550/2003 discusses the most common method of reducing the time required 0 of the molding cycle. One method shown is to keep the gla of the mold low to reduce the time required for cooling; However the disadvantage of this is that the surface quality of the molded galll is worse than if slow cooling is allowed. Also, rapid cooling induces huge retardation stress in the molded part. Hence cold molding is not suitable for example when molding precision parts along a long flow path. Often the resulting molded part is incomplete. Another problem 5 is that too rapid cooling of a molded sal in the cold mold can prevent crystallization of the resulting product and degrade the quality of the finished part. In some applications, injection can be induced by heating the injection mold. This can be done with heating rods; flames Cooling lines with cooling medium (such as water or oil) gn etc. In these models the Lal mold is kept during the mold cycle so that the molten plastic flows easier at catia but significantly dhe 0 the mold is cold Le enough to give a great deal of hardening to the plastic during cooling when the cavity lies cavity Patent Application No. 2003 [11550] rejects a system in which a coolant is alternately circulated after a heating fluid is circulated during a molding cycle; Where it is shown that a machine and a device in this way are complex dan, and also the time required for the molding cycle becomes longer. Alternatively an integrated cooling sleeve is provided. 5 The molding cycle includes injection feeding at high pressure; As in traditional injection molding methods and machines

other; Hence involving the resulting related defects; Such as the high pressure in the closed filled injection mold and the need for high clamping force. Furthermore it; The process requires significant power consumption (for induction heating and canal fluid circulation), which contributes to the fact that finished molded parts are very expensive. The use of certain layers and induction heating also leads to rapid wear of the molds.

Generally, injection molds are a kind of tool steel; Although stainless steel and aluminum molds are known to be suitable for certain applications. Aluminum molds have a relatively short shelf life in the number of mold cycles; However, they may be preferred for low-volume applications in conventional injection molding machines because mold manufacturing costs are low and mold manufacturing times are fast. It is known for example from German patent application No. 3,017,559

0 The use of aluminum for part of an injection mold; But not every full injection mold. High-volume steel molds are better than aluminum molds because steel is not equally susceptible to wear; damage deformation during injection and fixation cycles; Like aluminium. Hence, the mold materials are selected in light of the period; acceptable wear; sensitivity of the mold to expansion when subjected to oscillations and temperature changes; And for the plastic material to be used with it.

5 The Variotherm process involves some proposed solutions to the above defects by using heating//cooling fluids to control the temperature of the injection mold. The mold cavity wall is heated before magma is injected to a temperature that exceeds the glass transition temperature of the magma. The magma is then injected into the mould. He explains that the surface of the actually taper mold is also heated by the hot plastic molten during the injection process; Which indicates that magma is at a degree

higher temperature than injection mold; hence the heating fluid; lig can start to harden early. After filling the mold is cooled until the molded hall acquires the necessary deformation temperature. As confirmed immediately, the cooling of the hot plastic, daa, begins the magma entering the cavity; then developed by active cooling of the mold when the cavity has been completely filled; This continues until the plastic part has reached the desired deformation temperature. It is confirmed to drop to 9640 from

5 Injection pressure is provided by the Variotherm method Low clamping forces are also indicated. Although

Although the Variotherm dike was invented in the 1970s, the principles of Jie Variotherm oil heating/cooling and gas heating/cooling in injection molds are not widely applied. A novel approach to realize the local precise Variotherm process in micro ] injection molding”, Lei Xie, Thalke Niesel, Monika Leester—Schadel, Gerhard Ziegmann, Stephanus 8010600800, Microsyst Technol., 5

[Springer-Verlag Berlin Heidelberg 17 October 2012

Hochdorf (Ostring (SINGLE Temperiertechnik GmbH).

/ 61118 Variotherm process in The Alternating Temperature Technology (ATT) Cooling/heating channels in injection molds consist of two separate 51//15 ducts 0 closed “merged in ducts” Ell containing gle thermocouples of different temperatures. Both SWTS testers contained the same fluid. Water is considered favorable for temperatures up to 200 C; Whereas, the oil is suitable for very rare applications operating at temperatures up to 300°C. The system is equipped with an external valve station to convert the two streams from the bypass mode to the mold temperature control mode. The ducts are created by Lasercusing by accumulating layers of powder steel to form closed internal mold heating/cooling ducts whose marking lines are aligned. The heating/cooling ducts for the dies that characterize ATT applications are not drilled or milled into the metal. Some of the disadvantages of ATT include that these channels cannot be changed in relation to eg display; or accessing it for cleaning if it becomes clogged; Or to check its defects, which may occur, for example, as a result of corrosion ally due to the contact of the mold metal with the cooling / heating medium. Furthermore 0 the space between the cavity and the duct must be thick enough to avoid unintentional collapse when the pressurized heating/cooling medium passes through the ducts formed by laser fusion; when done

Forced mold plate clamping » and the possibility of resisting the pressure of magma injection. EP No. 0335388 relates to a method of injection molding whereby the temperature of the injection mold is raised above the melting point of the plasticizer by circulating a sale of a heat carrier prior to injection of the plasticizer into the injection mold. Carrier channels are formed by forming a gap between an insert

and cavity surface. The heat carrier flow is released through the injection mold when the plasticizer is injected into the injection mold. After the cavity is filled with plasticizer, the injection mold is cooled to a temperature below the freezing point of the plasticizer by appropriate circulation of the heat carrier. The flow of the heat carrier material through the injection mold is cut off when the material is injected into the cavity so that the temperature of the walls of the parts defining the cavity is not affected further. The passages of the heat-carrying material are used in the support during the introduction of the material, which makes the parts of the mold subject to reciprocal displacement and the leakage of the heat-carrying material into the gaps and cavities. US Patent No. 5,423,670 discloses a similar device and method. During the preparation of the plasticizer in the injection molding machine, the surface plate temperature of the cavity is raised to a level approximately equal to 0, the melting temperature of the material being molded. The tool cavity is heated rapidly and uniformly prior to insertion of the material into the cavity in order to reduce the injection pressures required to fill the cavity. Once material filling of the cavity is complete, the De fluid cools the cavity insert plate by removing the settled heat present in the cavity insert plate due to the preheating and latent heat stored in the molten plastic. US Patent #5,423,670 provides no indication of an appropriate 5 injection pressure. International Patent Application No. 74922/00 discloses a system and method combining multiple counter gates to reduce magma flow along the tracks and thus reduce the aspect ratio. The method comprises asymmetric temperature steps, the first of which is “heating the mold surfaces by circulating heat transfer fluids provided by a heated bypass system” to a specific temperature La high enough to inhibit solidification. after that secondly; 0 Inject magma through opposite portals; then thirdly; Cooling quickly to solidification by circulating heat transfer fluids of much lower temperature” and delivered from a cold bypass supply system. As such, lag each mold injection cycle with a heating phase, where Sh (Sh) is the rapid rise in mold surface temperature from a combination of high thermal conductivity metal mold cavity materials (preferably a copper alloy) plus A very large thermal driving force is provided by the hot side supply system 5 fluid (dia) vapor.This fluid has a degree Hla above solidification temperatures

The melt (Tg) or (Tm) that characterizes thermoplastic plastics. The heating and injection phase is followed by a cooling phase, Cus cam. The drop in surface molding temperature is thermally driven by cold side supply fluid temperatures (preferably water) less than The melt hardening temperatures (Tg) or (Tm) that are characteristic of thermoplastic plastics are much greater. The higher these temperature differences are, the faster this “asymmetric” molding cycle will be. To overcome problems with poor duplication of the mold surface in the product Molded Thermoplastic To maximize accurate reproduction of the finest surface lines and details, the constituent surfaces of the mold cavity portion of International Patent Application No. 0 are heated at least above the solid-to-liquid transition temperature characteristic of a thermoplastic polymer. thermoplastics such as polycarbonate and acrylics; the preferred set point is the 91855 (Tg) transition temperature. For thermoplastic crystalline polymers, the melting point (Tm) polymer is suggested. s melting point The preferred set temperature of the cavity surfaces is chosen to be high Le sufficient so that the thermoplastic gall that is molded does not form stably at any higher temperatures; Hence the hot-side fluid needs to be somewhat hotter than a certain temperature to keep the cavity surfaces above the specified temperature. Then, after the molding cavity has been “heavily filled” by the thermoplastic molten material and before the mold is opened at the cut-off line, the surface temperature of the mold is reduced to less than 19 OR TM ISBN 74922/00 implies Realizing the problem that the plastic feeding raw material is chan rigid and then 0 high injection pressure is required to fill the mould; Hence a high clamping force is also required to hold the mold parts in close contact. The mold in International Patent Application 74922/00 is designed for variable size molding cavities and has heating/cooling channels in the mold to withstand high clamping forces and high injection pressures. The back side of the mold does not change. The mechanical formation of said back side of the quenching channel formation does not provide for the air gaps necessary to maintain the essential property 5 of the variable size molding cavity; Nor does International Patent Application No. 74922/00 file

Suggestions for appropriate injection pressures.

Although some prior art gale briefly mention lower injection pressures relative to heating the injection mold prior to injection of magma, none of the prior Gill references give advice on appropriate injection pressures. All proposed prior art injection molds for this cooling system are complex structures; for example made up of many detailed components (Jie casings or parts) which are separated from each other by fins Cale) «ails ¢ blocks; shal distance pieces etc.; This results in a lot of vortex and unregulated retention time for the hardening fluid; or they are built-in channels that are costly to manufacture and cannot be inspected. All prior art references are compromises to the higher temperature used at injection; Given the time

and thermal energy required.

0 Depending on the die material, some prior art methods that rely on heat transfer and a high degree of vortex or rapid flow of fluid in metal channels can cause; jie water; to corrosive corrosion; flow-enhanced erosion; or even cavitation of the tempering channels; Which unavoidably shortens the life of the injection mold. The metal material between the quenching channel and the mold cavity may be deformed and the quenching channels may crack or deform during ll injection processing; when subjected to clamping force and compression

5 injections. The precise design of the injection mold is considered; controlling injection mold temperatures at different stages of the molding process; Choosing the injection pressure and routing the flow of the hardening medium properly is of the most importance. GENERAL DESCRIPTION OF THE INVENTION The object of the present invention is to remedy at least some of the defects indicated above in machines and methods

0 injection molding; Provide alternative methods and machines. In a first aspect of the present invention, an injection molding method is thus provided in which no clamping and/or bonding force is required; a large injection pressure and/or injection velocity is required when injecting the molten plastic material. In a second aspect the present invention provides a versatile plastic injection arrangement attached to an injection mold.

In a third aspect, the present invention provides a method in which the molding of molded plastic parts with very high mechanical features and properties is more advantageous than when using conventional injection molding machines and methods. In a fourth aspect, the present invention provides a method in which material waste is reduced compared to injection molding methods. In a fifth aspect, the present invention provides an injection molding method by which very thin-walled and/or geometrically complex plastic parts can be formed. In a sixth aspect, the present invention provides an injection molding method by which optically acceptable plastic parts can be formed. In a seventh aspect, the present invention provides an injection molding method by which several plastic parts may be formed simultaneously in an injection mold in the same injection molding cycle. 0 In an eighth aspect, the present invention provides an injection mold for the method and machine according to the present invention. In the context of the present invention it should be understood that an injection cycle is a complete, iterative sequence of injection molding operations for a plastic part. Cycle time is the time required for such a cycle; Including returning the machine and the system to repeat molding another part. An injection mold is a tool that has one or more molding cavities; of one or AST of the parts to be molded. The parts may be identical or different. As in 5 sets mould, or multi-cavity mould. The molding bore or bore is selected by opposing mortises; or a group of mortises in the two halves of the mold. The dimple is the outer surface of the product; Molded part or component. An injection molding plate identifies one half of the mold. The injector plate is fixed in the fixed clamping cylinder of the injection molding machine. The injection molding board is half of the corresponding mold. The diaphragm plate 0 is fixed with a movable clamping cylinder; It can be moved for example with a hydraulic piston. Clamping cylinders exert a clamping force that keeps the two halves of the injection mold close together during the molding cycle in response to the injection pressure imposed during injection of the magma into one or more molding cavities and imposed by the injected magma confined within the enclosed injection mold.

— 0 1 — The injection mold can be supplied with one or AST cores; Formed by bodies or protrusions that can be recesses and the inner surfaces of molded parts. The cores may be a permanent part of a cavity or be retractable. Retractable cores are used when extruding molding parts into molding recesses that are not perpendicular to the direction of extrusion of the part from the mold. The retractable kernels are automatically withdrawn from the mold before the mold is opened and reinserted when the mold is closed again and prior to injection. The tablet gia LOU is from an articulatory group with various articulatory means; INCLUDING ALOU NAILS - i.e. bars; nails or bushings that push a molded part off a core or out of a mold cavity-; “re-extruding screws”—that is, the projections that push the extruding assembly back with the mold closed—; and an effervescent rod” i.e. a beam that occupies the effervescent assembly when the injection mold is opened. and have run and function

0 Extruded assembly as in conventional injection molding machines and methods; They are not discussed further in the present invention. The injected plate may have more than one gate acting as a channel through which soft plastic or molten salad flows into the molding cavity; Including, but not limited to, a molding gate defining the passage through which the soft or molten plastic material flows from the injection nozzle into a bore.

5 mold or duct system. The term casting is also often used for the hardened plastic neck left over from the hardened molded galll pieces of the raceway or casting. A direct gate connects directly into one or more mold cavities. A gate on the edge represents the entrance to the molded part of the duct which is on the line separating the two halves of the mold. There may be more than one direct gate or one edge gate in the present invention.

0 represents the streams in the Ll channel injection mold where the casting is connected to the direct bore gate. Sometimes the term “gall” is also used for the plastic part formed in this channel. The raceways may be hot raceways and then in the two halves of the mold the raceways are isolated from the molding cavities aig to keep them heated continuously.

Within the context of the current application, the terms 'processing window' or 'plastic material processing window' can be used interchangeably. Glia is the temperature interval between the beginning of the glass transition and the beginning of the dissolution of the plastic material. Or 'sale dallas plastic window' is the melting temperature of a plastic material and the glass transition temperature interval. Provided with plastic material, data sheets containing information about the aforementioned "window". Some plastic feed materials consist of more than one plastic component and are composite materials using the different chemical and physical properties of the individual plastic components in a bonding or synergistic manner. 0 new plastics and plastic compounds are being developed all the time. It is important to note and adhere to the information in the data sheets. A preferred temperature within the curing window is 'processing dallas 636'. This is the temperature interval recommended by each manufacturer for working the plasticizer before entering the cavity. In injection molding, the plasticizer temperature is typically within this range. The separator at the exit from the nozzle of the injection molding machine heating feed screw. Significantly the separator is not set by the onset of glass transition or melting but is less than the onset of dissolution of the material. The term 'tempering medium' is used for a fluid chosen from suitable gases or liquids To carry a selected temperature for a suitable time to exchange thermal energy with the injection mold. Electric current and electromagnetic fields are excluded from the 'hardening medium' and from 0 heating any part of the injection mold also the Lad cally except for any heat core or stream. Is that the method includes the following steps: (a) Providing the injection molding machine with an injection mold that defines one or more molding cavities, where the injection mold includes an injector mold plate and a mold plate

— 1 2 —

reciprocating ejector mold plate; Where he cuts the back side of the one on

The bottom of the die plate has one or more open channels for circulating the hardening medium ¢

(b) Provide a first-temperature plasticizer feed within the plasticizer processing window;

(c) heat at least one or more of the molding cavities to a second temperature within the plastic sald cure window and hold the injection mold in Df Ala at said second temperature

By circulating a first solution having a third temperature through one or more channels 3

(d) Injecting the plasticizer having the first temperature into the closed heated mold to fill one or

over molding cavities;

(e) Cooling at least one or more of the molding cavities of the closed filled injection mold to a temperature

0 fourth less than the first shall degree until the molded plastic galll(s) are at least partially hardened within the injection mold by circulating a second hardening medium of fifth temperature through one or more of the channels; (f) Opening the injection mold by separating the ejector plate from the ejector plate;

(g) eject the hardened molded plastic part(s) at least partially by operating the effervescent nails from the effervescent plate ¢ and

5 (h)et Repeat the cycle of steps (c) - (g) until the desired number of plastic parts has been produced. By the term “open channel of a plate 0060” it should be implied within the context of the present invention that either an injection plate or an extruder plate has a channel that remains open until it is closed by part ie ¢ AT another plate or cylinder of the injection molding tool or injection molding machine; To act as one or more channels to circulate the hardening medium. In this way, the hardening channels mentioned in are first constructed

0 of the present invention is final once the die plates are in position from the tool or machine. Tempering channels can be opened for inspection.

Deforming marks on an injection molded oa are nearly unavoidable in conventional injection molding methods. (Sag) that these marks are for example dividing lines on the molded gall showing the point where the two halves of the injection molding meet in the closure; flaps; any flakes of plasticine flowing out of the molding cavity; or castings resulting from the feed hole in the molding Injection mold between the injection nozzle and one or AST of the molding cavities and/or duct system; gate marks that form on the gate of channels through which melt plastic flows from the stream into one or AST of the molding cavities; or bolt marks Extrusions that are lag marks on the molded gall due to the profile of the caliper.Extrusions may for example form from misalignment and clearances of the mold plates; and/or from dimensional differences in the coupling surfaces of the molding cavities 0 when in the closed position of the injection mold in contact In conventional injection molding machines Lan has dimensional variations eg due to irregular deformation; pressure induced during injection; injection mold processing tolerances (WT) and irregular thermal expansion and contraction of the (QE) halves as they are subjected to rapid cycles during the injection phases » packing; capil) and articulation in the injection molding cycle. Because these marks are nearly unavoidable, their solution was to design the two halves of the 5 injection mold in such a way that the marks would form in areas hidden from view in the final molded part use. In the manner according to the present invention deformable and harmful marks can be largely avoided because the injection mold has already been heated to the second temperature by circulating the tempering medium within one or more open channels provided at the back side of any of the injection mold plates or extruders. 0 Ensure that the quenching channels are open so that the respective panels are coupled with another injection molded Al panel as this slab acts as a cover for the quenching channels. Usually it is not necessary to preform the injection mold board specifically. In this way a very versatile heating/cooling system can be created in an injection mold. The channels on the back side of the die plate are unique to the die; Not an injection molding machine.

when the plasticizer is injected at the first temperature into a closed injection mold; The plasticizer in dlls is soft; viscous and processable” e.g. as magma; The injection mold being at the second temperature; Which is also considered within the plastic material treatment window. In this way premature hardening of the heated plasticizer in the gates is prevented; pours or sewers; and any one or more molding cavities. The hot plastic material flows almost by itself into one or more molding cavities without the need to apply high injection pressure and/or clamping forces close to even those of conventional injection molding methods. In fact the injection pressure imposed on the present invention is at least 9630 less than that of the conventional injection pressure. This eliminates the problem of unintentional plate separation which induces deformation by flaps on the molded parts. The lower strength also allows for the use of more ductile materials

0 for template; Smaller, thinner mold plates with finer inner walls; More than 0% lighter mold plates and weaker bonding arrangements on the molding machine compared to a conventional injection molding machine. The pressure imposed by the plasticizer is on the side of the injection screw or the hydraulic piston when the plasticizer is injected into the injection mould, and the friction is reduced compared to traditional injection molding methods and machines. injection molding pressure; Hence the pressure imposed on the screw to compress and insert the plastic material at a degree

5 first heat in a hydraulic press to completely fill one or more molding cavities; Smaller than traditional injection molding methods and machines. It should be understood that the hydraulic piston represents the forward movement of the screw inside the feeding cylinder to force the plasticizer at the initial temperature through a nozzle into one or more molding cavity through gates; Pours and sewers. The sewers, for example, may be hot sewers; Hence further crumb formation is prevented.

0 By the method of the present invention the plastic part(s) may be manufactured without at least one or more cast removals; Floating lines on the plastic galleries ¢ The converging lines in the plastic parts behind the tool cores” and the tension in the molded plastic parts. And due to the ability to flow into the injection mold in the hot state of the viscous soft plastic material at temperatures within the curing window, a very homogeneous and rapid distribution of the plastic material 0, for example, in the form of magma; in one or more

5. From the cavities, self-Adel uj, and the part (shall) molded by the final injection, which is hardened

— 5 1 — Obtaining it in this way is uniform and not subject to warping” i.e. deformation resulting from irregular internal stresses. Allows one or more channels to be provided in the slab (Bal) forming one half of the fixed mould; and/or in the Cua plate (LDU) forming half of the movable mold; “circulating hot hardening media” or “yb” respectively; to maintain the desired exchange temperatures for the injection mold; namely, hot first during injection of the plasticizer; then cold to harden the part(s). ) is molded into one or more molding recesses to complete an injection cycle.This provides an inexpensive, simple yet standardized method of adjusting the temperature of an injection mold with a backside of open hardening channels to any preferred temperature.The second temperature may be at any Preferred embodiment is greater than or equal to the first temperature »0 Although the invention is suitable for some plastic materials even if the second temperature is lower than the first temperature but within the window of treatment of the plastic material.In any preferred embodiment the fifth temperature can also be lower than the third temperature, or even less than the lowest temperature in the plasticizing window, and/or the fourth temperature can be less than the lowest Sha degree in the plasticizing window. Glass transition temperature 5 and higher Temp is the temperature at which fas the plasticizer is in decomposition. The correct selection of the first and second temperatures is made; third; the fourth and fifth based on the data of the Lad material providers relates to the selected plastic material processing window in goa the possible processing conditions to obtain the plastic gall (parts) le quality given in the present invention; hence the plastic part(s) having the desired design; measurements; accurate dimensions and shapes; Wella Famous Labels or Famous Labels Limited produces the lowest manufacturing times and costs possible. It may be preferable in steps (e) and (g) to subject the molded plastic parts to near-total or complete hardening prior to extrusion. This ensures that the countersunk screw(s) do not make unwanted marks on the molded part. However, some plastic materials can reach, before complete hardening, a partially solid Ala in which the molded part has a temperature below the curing window and can be extruded for final hardening outside the injection mold without losing the desired shape or design; They make marks or clicks

as a result of contact with the extrusive nails. Casting of the molded part(s) is performed even before complete hardening

to increase the speed and rate of manufacturing; It reduces manufacturing costs.

The viscosity of a magma increases with increasing molecular weight; Thus the required injection pressure and molding pressure increases

naturally in conventional injection molding methods and machines to fill any specific geometry of a molding cavity

By increasing plastic materials that have a very high molecular weight.

Thermoplastic materials are particularly suitable for use in the incoming injection molding method

In the present invention simply by adjusting the first and second temperatures; (AE fourth and fifth

appropriately; The weight of the jigsaw can be taken into account by the muzzled shape.

Dellin® Jia (Sa) obtained from DuPont provided a first example of plastic polymers 10 for use in the present invention. Delrin® resins acetal

acetal are semi-crystalline polymers; Thermoplastics that polymerize

formaldehyde; polymerization of formaldehyde; which is also commonly referred to as

Polyoxymethylene (POM) polyoxymethylene according to data sheet (DuPont™ resin).

Delrin® Acetal (TECHNICAL INFORMATION « acetal) Delrin® contains 5 very low amorphous content that makes the glass transition temperature effect

TQ is marginal and very difficult to measure. For ©0610 acetal homopolymers it is pg

The melting temperature Tm "melting temperature" is 8 °C and the curing window

The preferred stereotype Sle is from 210-220 m; From which the first temperature can be selected.

Other examples include polypropylenes such as those obtained 0 from INEOS 016105 & Polymers USA, 2600 South Shore Boulevard, League

INEOS 016705 & Material Provider Statements 484 Ww, .City, TX 3

(Polymers USA, Polypropylene Processing Guide) Polypropylene compounds

Polypropylene is a semi-crystalline polymer with a favorable dallas window.

It is about 204 - 268 AD.

Other examples are the high-temperature thermoplastic amorphous sulfone polymers that can be obtained from Solvay Specialty Polymers USA, LLC, 4500 McGinnis Ferry Road, Alpharetta, GA 30005-USA. 3914. According to the material providers data sheet (Processing Guide, Radel® PPSU, Veradel® PESU, Udel® PSU, Acudel® modified PPSU 5). The recommended processing window is 138-350 m. The above examples are non-existent. Exclusive to the resins and elastomers suitable for use in the present invention.In method Tg of the present invention there is no need to excessively increase the injection pressure and molding pressure to 0 to accommodate high molecular weight polymers and the method according to the present invention is not limited to specific thermoplastic polymeric materials. Special Due to the provision of channels in the back side of the mold plates, the injected plasticizer and the injection mold are typically at substantially the same temperature when filling the molding cavities to keep the plasticizer in the same condition. The temperature in the present invention carefully to ensure that the properties of viscosity, ductility, and flow Lillie are therefore satisfactory and sufficient for the plasticizing material, having a temperature within the curing window, to be easily distributed. into one or more molding cavities. The first temperature » second temperature and/or third temperature shall be regulated and controlled by the hardening medium flowing close to one or more of the molding bores due to the open tempering channels to prevent unintentional temperature drop(s). Yl after the shot is completed; Injection and filling of 0 one or more molding cavities; The injection mold temperature is lowered to the fourth temperature by circulating the second hardening medium at the fifth temperature through one or more channels. So the temperatures in the method are set appropriately in advance according to the properties of the plastic material. Ji current invention or completely eliminates the need to apply high pressure. And because the temperatures of the first and second hardening media can be controlled away from the injection mold, despite the temperature chosen

— 1 8 —

And predetermined to adjust the molding cavity temperatures the said temperatures are fast and fast

Adapt to different processing windows of various different plastic materials.

As mentioned above one or more channels can preferably be provided adjacent to one or more cavities

Molding » Preferably close to the molding surface of one or more molding cavities so that overflow occurs

high thermal conductivity and heat conduction between molded (gad) (parts); sale injection mold tool

And the middle of the first and second corresponding hardening »quickly; efficiently and in a coherent manner.

Even complex molded gall (parts) can be formed without additional effort due to thermal energy management

and heat exchange of injection mold » hardening media and plasticizer better according to the present invention.

Examples of complex molded parts that are not yet possible to manufacture by conventional injection molding in large numbers at low costs include the following:

Parts in the form of tubes having circular cross-sections. And the parts that are in the form of circular tubes

actually; While all parts in the form of tubes that are manufactured by molding methods and machines

With conventional injections, without exception, oval cross-sections, Wis

- In injection molded plastic parts that are box-shaped, the walls do not shrink and fold inward towards the center of the box.

- Injection molded plastic parts can be made with long narrow recesses; Because it can be used

Long thin cores with only one end clamping, although double end clamping is possible

Lad and

- Shall can be made asymmetrically injection molded hence requiring centerline asymmetrical molding bores without holes/leakage/venting.

Jian is another advantage of having an injection mold at a second temperature when it receives the plasticine shot at

da first heat in that it allows the injection mold to have an injection gate off center. in no way

The canals can flow the soft plastic material at the initial temperature unobstructed regardless of the

injection portal site; So an off-center injection gate works just as a center injection gate does. As such, the invention is largely independent of the portal site; This gate can even be configurable or SST can exist from a single injection gate. So the hice of the tool has a pS level of freedom in choosing the position of the point in the cast; i.e. a gate that extends into a cavity can be installed; And injection mold on various injection molding machines. Provision of one or more channels in the injection plate and/or extruder plate makes it possible to heat and cool one or more of the molding cavities as well as the molded plastic (shall) sad uniformly during a molding cycle. All the final molded plastic(s) Also en is equal contraction in all directions; any isotropic contraction; so that the shape of the molded 0 part(s) fully reflects the shape of one or more of the recesses; It allows the formation, for example, of fine pellets and cavities with a more rounded cross-section. In a highly preferred embodiment of the method according to the present invention step (c) may also comprise heating the conveyor system for feeding the plasticizer at any position prior to the injection mold to the temperature within the plasticizer curing window eg first temperature or “SST” preferably 5 Heating the entire conveyor system; So that the plasticizer feedstock is immediately brought to the first temperature. In this embodiment, the clamping force and clamping pressure imposed on the injection mold to keep it closed during the injection step (c) and the molding cycle in steps (c) - (g) are much less than for conventional injection molding methods and machines. Also, the fluid pressure of the plasticizer within one or more of the The molding cavities and the duct system will be reduced due to the selection of the first and second temperatures from window 0. Processing of the plastic material; And it drops even lower than the 9630 of conventional force and pressure. Hence any fluid pressure of the plasticizer at the temperature within the curing window needs to be compensated to only a marginal extent by the clamping force and clamping pressure of an injection molding machine incorporating a conveyor system designed to raise the temperature of the plasticizer feed during delivery and at the initial temperature when the feed reaches the gate Injecting the closed injection mold is also heated. A closed injection mold 5 for example may have substantially the same temperature as the incoming flow from the plasticizer feed.

— 0 2 — With the exception of smaller molds including prior art Al systems use alternate heating/cooling in plastic injection molding between high cost/complexity; and longer cycle times” at lower high injection temperatures. In practice, it is operated so that the mold cavities are at temperatures at which the plasticizing material is injected more easily than traditionally; sometimes it is fused; But under the article processing window. In step (c) air may be discharged from one or more of the molding chambers prior to proceeding with step (d) to prevent air entrapment in the molded plastic part. due to the low installation pressure; clamping force and pressure of fluid plastic in a closed injection mold; Significantly reduces wear of injection mold halves and splinters; Any leakage of plastic material from the cavity. Sarg one configuration of injection plate and extruder plate or both for example from a material such as aluminum | 0 or aluminum ingots” are not usually suitable for high production numbers using conventional methods due to very rapid wear of the injection mold and dimensional instability. Because both the injection mold and the plastic feeding are lala, the cycle time is short so that the aluminum injection mold is cooled before losing dimensional shape. The choice of aluminum as tool material has no or marginal effect on the dad and shapes of one or more molding cavities; Hence this same applies to the resulting molded parts. 5 Aluminum also provides high thermal conductivity between the cavity and the hardening medium; » And easy to process automatically when making the mold. The higher the thermal conductivity of the mold/tool material, the better the temperature gain of the rotary quenching medium will be achieved by the mold. The thermal conductivity of stainless steel (faa) is 16 W/(m"K), while aluminum has a thermal conductivity of 225 W/(m"K); Copper has a thermal conductivity of 392 W/(m K). The corresponding modulus of elasticity to steel is 0 200 GPa, aluminum 69 GPa and Copper 117 GPa. But although aluminum and copper have a lower modulus of elasticity than steel; Hence the die sheet is less able eg to retain the compressive forces etc. This fact is not a problem as higher compressive strength is not a requirement.In step (d) the molten plastic can be injected at an injection pressure of less than 200 kg/m. 5 cm2; preferably less than 100 kg/m2; preferably less than 80 kg/cm2; preferably less

from 60 kg/cm2; Even better at injection pressures between 20 and 50 kg/cm2. Traditional injection molding methods require an injection pressure of 600-700 kg/cm2; This is lel 15-30 times and then more (Als and requires more energy die ing early start to wear parts ally injection mold. Variotherm process and prior art systems using heating//cooling exchange In plastic injection molding methods at an injection pressure of about 200-250 kg/m2;therefore at a pressure much higher than that of the present invention.Cold deformation is seen in conventional injection molding methods.Cold deformation causes pad marks to form and contact lines” especially behind the cores or portions of the cores. Because the fully injection molding ly of the present invention is kept at a temperature within the curing window until the soft plastic material has fused into a homogeneous mass behind the cores; and for complete packing of the duct system and one or more molding cavities to occur Tag cannot be hardened early in a way that allows deformation to occur, call marks, welding marks and converging lines. Injection and distribution of 5 cycle Algo lap» and then at least for the period of steps (c) and (d). At least the third temperature for example may be the glass transition temperature of the elastomer; i.e. at least 0m; or even at least 300 m. Tempering channels facilitate this high temperature retention at the slightest thermal fluctuations. However lower temperatures of the first curing medium may be used in the case where the selected 0 plasticizer has a corresponding lower thermal energy utilization requirement in order to be curable within its curing window to an acceptable level. For the production of polyvinyl chloride parts 0010806 polyvinyl Las may be 140 - 180 m for example. and the first hardening medium circulating in one or more of the channels may preferably be oil.” Although the present invention comprises gal hardening media that are liquids; jie water; or gases. The two suitable Sly 5 first tempering mediums are selected to have sufficient heat capacity to carry at least the thermal energy into the mold cavities

— 2 2 — and at least of molded gall; Respectively"; For the manufacture of molded parts at high speed without compromising the physical and mechanical properties (jal) of the final mold. Those skilled in the art realize that testing and experimentation may be required to establish the optimal process parameters for a given injection molding job. The quenching medium f of the first and the second quenching medium may be cycled through the same channel or different channels of one or more of the channels; Optionally in response to the opening and closing of one or more valves associated with the corresponding inlets of one or more valves. If the first and second quenching mediums are circulated through one or more different channels in plate sense 3 the second quenching medium may be any dud medium other than calla including water or gas. 0 The first tempering medium may circulate in a first duct of one or more of the ducts different from a second duct of one or more of the ducts for cooling by the second tempering medium. This model is suitable if the duct system is designed as heat ducts. Any hardening medium with suitable dha properties and with the ability to circulate can be used in one or more of the channels; as described above; Including gases and liquids. 5 The third and fifth temperatures of the corresponding first and second hardening mediums are chosen depending on the first temperatures; second and third. It depends on the desired rate and speed of hardening. The temperatures chosen can affect the molding cycle time. Syringe plates having an off-center syringe gate are considered within the scope of the present invention. As a result of the easy flow and rapid distribution of the plasticizer in the duct system and one or more molding cavities; 0 where the plasticizer has an initial temperature within the curing window » The location of the injection gate and nozzle is not critical to obtaining a uniform and rapid distribution of the heated plasticizer into one or more cavities of the injection mold. Such an injection plate can even be used with various injection molding machines; Without dala to take special precautions for the location of the nozzle or the need for a special design HU and the plasticizer ¢ which has an initial temperature can be directed within the curing window; To the preferred portal for filling

— 3 2 — Specific cavity before others. It is also possible to have more nozzles with more injecting gates and “ST” edge gates, which allows injection into several molding cavities at the same time. The injection mold can be divided into two or more independent sections, each with its own individual injector nozzles and gates. In such an embodiment (Sa) different plasticizing materials, for example having the same thermal properties, are injected into each section “and manufacture one type of part” or different types of parts; or combinations of parts simultaneously. In a preferred embodiment any of the hardening medium flows the first or second hardening medium in one or more open channels of either an extrusion die plate or an injection die plate designed as a continuous channel having an inlet at a free edge of the opposite die plate and an outlet at an opposite free edge; wherein one or more open channels are between the inlet and the outlet They are narrow obstructions with turns in 0 opposite directions; these narrow turns are defined by a number of upright walls defining the two legs of the canal; preferably at least some of the upright walls are substantially parallel. channel legs between 6.0 and 30 mm; - number of channel legs between 3 and 10; 5 - channel leg lengths approximately 200 mm; - total length between 600 and 8005" - depth from 20 to 60 mm; - channel leg widths between 20 and 60 mm 3.0 and 5.0mm;- The channel shank thickness ranges from 5 3 to 0.5 millimeter; 0 - The thickness of the metal components between the channel and the molding cavity is between 3.0 and 5.5 pe.

— 4 2 — By testing with respect to best performance the inventors of the present invention realize that by using a conventional machining tool a satisfactory open channel at the rear side of an optimum performance die plate has the following characteristics - a channel leg with a length of about 140 mm; - five channel legs - total length of 700 mm; - depth is about 20 - 40 mm; - 4.2mm wide channel leg; - channel leg with a thickness of 3.8 mm; Slaw - metal components between slat) and molding cavity is 0.4 mm.

0 The operating parameters of the first ideal cycle time are a second ha degree about 20 m higher than the first temperature. Also, the fifth temperature should be at least 20 mm lower or greater than the fourth temperature. Preferably the second temperature is 20 C higher than the first temperature and the fifth temperature is 20 C lower than the fourth temperature. A suitable second hardening medium is a mineral oil having a fifth temperature of 40 °C or less;

5 optionally 30 m. The invention also relates to an injection mold comprising an injector mold plate and a reciprocating die plate. These two plates define one or more molding cavities in the case of the injection mold being closed. At least one of the panels shall have a back side with one or more open channels designed for: - during the injection of the plasticizer; It is at a first temperature within the plastic material treatment window

0 mentioned; Circulation in one or more molding cavities of a first hardening medium having a temperature of three degrees Celsius

— 2 5 —

At least the temperature within the injection molding material curing window to heat one or more of the

molding cavities to a second temperature; And

For at least partial hardening of the molded plastic parts inside the injection mold, a second hardening medium should be circulated to it.

A fifth temperature chosen for cooling at least one or more molding cavities in a mould

The syringe is packed closed to a fourth temperature lower than the first temperature.

And the fifth temperature can be appropriately lower than the third temperature to ensure solidification.

Optionally the fifth temperature is lower than the lowest temperature in the curing window; where access is made

to the fifth temperature at the end of the injection molding cycle

One or more open channels provided at the back of an injector plate or corresponding BEY 0 in a preferred embodiment may surround one or more molding recesses close to the molding recesses

mentioned to allow very rapid heat exchange between the hardening medium and the plasticizing material in one or more of the

cavities»; Hence obtaining a fast molding cycle time.

In a preferred embodiment one or more open channels are designed from either the die plate or the

The injection molding board as a channel is connected in the back side of the respective board. This connected channel 5 has an inlet at a free edge of the corresponding die plate and an exit at an opposite free edge; and component section

From one or more open channels between the inlet and the outlet is a narrow obstruction that spins in

Allie directions where tight turns are defined by a set of upright walls

LE legs specify preferably that some of the list walls are substantially parallel. BUS

Connected as such directed flow between inlet and outlet has minimal vortex and hence minimal 0 potential for metal wear.

One or more channels may have the same or individual inputs to an interpretation medium, depending on what

If the first and second tempering mediums are compatible, and whether their corresponding heat capacities are none

Marginal mutual mitigation effect.

— 6 2 — In a preferred embodiment the injected plate has one continuous first curing channel and the extruding plate has one continuous second curing channel to provide maximum direction and residence time for the first and second curing medium” The first and second curing media are the same or different; In addition to perfect heat transfer through the wall between the channel base and all mold cavities. The single continuous first quenching channel and the single continuous second quenching channel may be obstructed by narrow turns; preferably rounds of about 180" m. A preferred injection mold is described in Applicant's Joint Provisional European Patent Application No. (14162238.1)"; the following international patent is entitled "An injection mold, injection molding tool comprising the injection mold, methods of theirs “uses and objects obtained 10 filed on November 4, 2014 One or more valves can be attached to one or more channels as a means of switching between the circulation of the first hardening medium and the second hardening medium for heating and cooling, respectively; parts with connection of the injection mold or the complete injection mold during the injection molding cycle The 3rd and 5th temperatures can be controlled using eg a separate external heat exchanger or other heating/cooling arrangements 5 A mixed cooling manifold can be used and heat the cul medium if applicable; instead of or as a means of transfer to achieve intermediate temperatures; or time transfers; jie gradations. An injection molding machine preferred for use in the injection molding method described above may comprise: - the injection mold shown the designer above; 0 - Heating system for heating a conveyor system for feeding the plasticizer at any location prior to the injection mold to at least a temperature within the plasticizer handling window; - a pump arrangement to circulate the first curing medium of a third temperature and the second curing medium of a fifth temperature circulates through one or more channels in the injection mould; And

- Valve system to control the conversion between the first and second hardening media. Also, by heating the conveyor system in the injection molding machine to at least the temperature within the plasticizer processing window “Jie first temperature”, the sensitivity of the injection mold to temperature fluctuations in response to the injection of the plasticizer into the closed mold is greatly reduced. ats appropriately using the sale rheological properties of plastics at a temperature within the curing window during delivery; Injection and distribution within one or more molding cavities and duct system. So is the time interval required for the screw to rotate; or a hydraulic piston creates a shot; return to the original position; i.e. extraction time; Less if the solid feed is delivered through a long oda of the screw or hydraulic piston cylinder. 0 Clamping force and injection pressure can be kept to a minimum due to the injection of a fluid low viscosity plasticizer into the injection mold. Frictional wear is also reduced, at least in the cylinder; screw and/or hydraulic plunger” and any other components of the ddl tool and general machine wear; more so when operating with the plasticizer as a low viscosity fluid over the entire length of the injection molding machine” and the entire portion of the molding cycle; And until the first curing medium in one or more 5 channels is replaced by the second curing medium to start curing. The life of the injection mold and injection molding machine is generally extended compared to traditional injection molding eV operating at the higher injection pressures shown above. Variants of traditional injection molding methods and machines that cause deformation and stress marks on the finished molded part are eliminated; Or at least they are reduced to an insignificant minimum. Hence, when using the method and machine mentioned in the present invention, the tool designer has great freedom 0 in designing the tool parts in the injection mold due to the lack of deformation marks on the injection molded Ally Ale, which should be hidden from the consumer's eyes. Due to the provided arrangement of pumps and valve system very effective cooling of the injection molded part(s) can be achieved. The cooling gradient is fixed to the injector plate area to a large extent. No unwanted differential cooling can occur for an area of the molded iad cooled at a significantly different rate; 5 And none of the mold surfaces have different temperatures. Hence the flexion; that could happen

das differential cooling; Not a problem. If an injection molded EIS surface begins to separate into

Layers As a result of cooling the aforementioned layers one by one, he may suddenly see layers or appearance

resembling fish scales; However because differential cooling through injection molded gall thickness does not occur

In an injection molded part manufactured according to Jal's invention, there is no danger of the formation of an injection molded part

5 turns into chips as well. There is no evidence in the injection molded gall (parts) being obtained

it by injection molding method and injection molding according to invention Ma on the groove or other

Markings on the surfaces of the molded portion show directions of magma flow or impact.

The alternate heating and cooling system of the injection mold of the present invention also provides dimensional stability

Final injection molded part(s). The exact shape of the part(s) and the corresponding injection molding cavity symmetry are preserved; Mall The finished injection molded gall is in line with

Injection molded cavity.

The present invention further relates to the molded part(s) obtained by any of the methods;

and/or injection mould; and/or the injection molding machine described above. Some examples are given below. And done

Emphasize that these are examples of complex parts that are usually problematic to manufacture at low costs and at high speed using conventional injection molding methods and machines. And therefore not considered

Examples are an exclusive list.

The shrinkage is Sas Sli cooling of a 4 cm thick injection molded part without loss of dimensional stability

changes in transparency. In Alla injection molded bodies more San heating can be done

and simply cooling of half extruder die plate and half injection die plate; Respectively; For 0 to obtain a final molded solid unit with a thickness of approximately 8 cm.

It is also possible to injection mold a completely transparent ball. The two sensitive cooling system and method in

The present invention hardens the soft plastic without crystallization causing, for example, it to become a ball

opaque solid As often happens in traditional injection molding methods.

— 2 9 —

An injection molding machine may also usefully incorporate an electronically controlled operating system

with a computer program to control the continuous injection molding cycle to obtain a plastic part; in a form

Preferred thermoplastic part.

Multiple different plastic parts can be injection molded into the same injection mold in an injection molding cycle

one. Low pressure and high temperature during injection allow uneven packing of one or more

of cavities and af regions thereof without inducing twisting mechanical die load or leakage which is

in traditional injection molding and methods. For parts kits this allows for much lower costs - one mould

lly (dad) Only one injection mold cycle per part assembly; for the entire kit.

It should be understood that any features described in relation to the injection molding method can be implemented in either an injection molding machine or an injection mold and vice versa.

Brief description of the graphics

More details of one or more die plate channels are shown for use with the method in

The present invention is in the form where:

Figure 1 shows an injection mold plate visible from the face of the mold cavity; 5 Fig. 2 shows the same panel visible from the reverse side;

Fig. 3 shows a mold plate visible from the face of the mold cavity; And

Figure 4 shows the same panel visible from the reverse side.

Detailed description:

An injector mold plate 2 and an ejector mold plate LY 3 0 together form an injection mold 1 and are described below jointly for all shapes.

— 3 0 —

The injector die plate 2 shown in Figures 1 and 2 comprises the first injector die plate face 4 and a back side

Is a second injection mold board face 5 vs. The die plate includes 3 faces of the LOU die plate

The first 6 and the back side is the face of a second vocal block board 7 opposite. The face of the injection mold board is edging

1st 4 forward towards the face of the 1st vocal die board 6; For defining and constraining mold cavities 8 a 8

'z 8 5 8 d while the injection mold is in Als Close. Mold cavities are 8 a 8” 8 z

8 d by means of the first die half-recesses 8 81 870 c” formed in the face of the die plate

The first injector 4 of the injector die plate 2 and the second complementary die halves

8d Leal, 280778718 in front of the first verbal template plate 6 of the verbal template plate 3.

And the face of the second injection mold board has 5 first peripheral zone 9 with a first circumferential gap 10 for a barrier 0 1 first leak to enclose slay heating/cooling 1 1 continuous first one on f less to rotate ventilating medium at

Close the injection mold.

The las shape has the face of the second invoking die plate 7 of the invoking die plate 3 a second peripheral region

2 has a second circumferential gap 13 of a second seal surrounding at least one second conduit 14.

The die plate LU 3 houses a set of 15 traverse passages for ejector pins (not shown); It includes 15 transverse lanes for screws

Note (pe) indicated) Passage seals 16 to prevent leakage of the hardening medium from

The second channel 14 when the molded plastic gia resonates in step (g).

The injection mold plate includes 2 tempering medium inlets of the first 17 and 1 medium outlet

First hardening 18 are provided through opposite edges 20621 of the injection molding plate and connect 0 through the first hardening medium channel 11. The die plate LOU 3 comprises a second hardening medium inlet 22 and an outlet

A second hardening medium 23 is provided through the two edges 24; 25 for the stylized molding board and two cross-links

14. The location of the entrances and exits can be another suitable place, including:

That's another edge.

Injection gate 26 connects to mold cavities 8a 8b; 8c; 8 d defined by mold half-recesses 8 Cl 8 B 8 A 3 8 B 8 C “”; 8 d “” through the sewer. The channel of the first tempering center includes 11 free openings, the first 27 along its length, which defines a course (gal), a narrow winding obstacle with turns defined by the walls of the channel 28a, 28b, 28c; 28 d. The first peripheral area 9 which encloses the first hardening medium channel 11 allows the circulation of hot or cold hardening medium from a first hardening medium source; Where the mentioned first tempering medium is the same or different in cooling or heating, respectively. The first hardening medium is connected to the injection mold plate 2 through the first hardening medium inlet 7 as shown by arrow a. Yas 0 flows into the first hardening medium; as indicated by arrows aod 3; b 4 b 5; B 6 « B 7 B 8; the length of curvature of the first adjacent leg 11 of second leg 11 b; third leg 1c; fourth leg 11 d; 5th leg 11 ca, 6th leg 11a and 7th 11g of narrow zigzag turns connected from the first hardening center channel 11; defined by the channel walls 28 J “a 8 28 c; 28d over one or more of the mold cavities 8a:8b8:7c” up to gar 1st offsetting medium 5 through the first offsetting medium exit 18; on the ill indicated by the arrow ©; It returns to the relevant source for heat exchange and/or quenching before participating in a subsequent quenching cycle. The first tempering medium can; due to the design; Lay in that curvature; Different lengths and depths in light of the position of the mold cavities from the first hardening medium channel 11) Sweep a very large area of the injection mold plate 2 next to one or SST of the mold cavities 018 8 b: 8 Jz 0 and BTM with ease of adjustment The residence time of the first curing medium in the first curing medium channel 11, for example by controlling the speed system, starting and stopping, or other alternatives.As a result of the large swept area Gob magma inside the mold cavities, the heat by the first curing medium is rapidly It is highly effective and regular.It can be a few cycles of the first tempering medium

— 3 2 —

Sufficient for one injection molding cycle. In this way, the injection molding plate 2 is given a unique and multiple quenching system

Uses” (Sarg) can be easily adjusted according to the method of the present invention.

Injection molds 1 [EEO] are kept in a refining medium “such as lubricated oil”; 3 During injection, it was cooled with medium

Tempering before and at least until the beginning of opening the injection mold 1 for the injection molded gall. No preheating required

The exchange cooling of each injector die plate 2 and extruder die plate 3 or both must be synchronized although this

Mostly that is what happens. For example once the injector die plate 2 and the ejector die plate are spaced

3 To start pronouncing the molded part (edad) the injection mold plate heating can be started again to prepare the plate

Injector mold 2 for the next molding cycle. Premature solidification of magma can easily be avoided as a result

The flow of the hardening medium through the channels of the hardening media; This facilitates the flow of low viscosity 0 melt to fill one or more of the mold cavities in the fully enclosed mold.

The potential rapid thermal management according to the present invention of die plates and die cavities leads to

Facilitate the cooling and heating of the injection die plate 2 and the LOU die plate 3 and thus easier set-up and follow-up

An experimental thermal management scheme and/or timeline to be based in theory or only shal tests

and experiments to obtain high quality molded plastic parts. It also supports thermal cycling in accordance with 5 of the present invention and optimizes alternate cooling and heating so that the molded plastic parts are complete; Such as

molded plastic parts (dad) ie molded plastic parts having wall thickness

J of 1 cae or complex molded plastic parts available; Ally is almost impossible to manufacture

cost-effective way compared to conventional injection molding.

Figure 2 shows the injection molding plate 2 from the face of the first injection molding plate 4; With the middle exit 0 the first tempering 18 in the lower left corner.

Two rectangular mortises 8 CT 8b” are provided; for example by mechanization; In ang the injection mold board

1st 4 of injection mold plate 2 to serve as 1st die halves 8 80 b”. dig

Provide a third tap 8c’ as half of the first die cavity AT 8c dens’ on a separate tool core insert

Removable 29 from the side of the injection mold plate 2 to form a mold gia with a long transverse recess. The tool core 29 is not yet in its opposite part of the mold cavity 8 Cz Fig. 3 The mold plate LOU 3 is visible from the face of the plate The second mold LOU 7 is inclined from the short edge that has the outlet of the second hardening medium 23. The channel of the second hardening medium 14 has a second free opening 30 along its length that determines the flow path; Zigzag continuous obstruction of narrow turns defined by canal walls 31 of 31 b » 31 oz 31 d. It includes the second peripheral zone 12 that surrounds the second quenching medium channel 14 with a second cavity 32 to receive a second leakage pile 13. The second quenching medium channel 14” is the same as the first quenching medium channel 11; Designed to allow the flow of hardening medium through the two adjacent legs of the obstruction between the second hardening medium inlet 22; As 0 indicated by the arrow Cr and the second hardening medium outlet 23; as shown by arrow 1 and then along the track from the entrance of the second hardening medium 22 through an eighth leg 14a; ninth leg 14 b; tenth leg 14c; eleventh leg 14 2 tenth second leg 14 a thirteenth leg 14 and fourteenth leg 14 g of hindrance; as shown by arrows od 051 b 53 002 b 4; B 55 B 766 B 27 B 8 Provide cross-pass assembly 15 for blisters in 5 components of channel walls 31 a 31 b” 31 x 31 d of stub slab 3 between 8th leg 4a 9th leg 14 co leg sald) 14c; Eleventh leg 14 d twelfth leg 14 ca thirteenth leg 14 f and fourteenth leg 14 g of hitch. Fig. 4 shows the ejection die plate 3 from the face of the first ejection die plate 6 to illustrate the different half-recesses of the second die 8 1 (8 B 8 U x 8D”). Connecting a duct system 32; eg a duct system heated using a channel of the second hardening medium 14 mold recesses 8a 8b 8c 8d with an orifice (not shown) at injection gate 26 shown in Fig. 1 for dispensing magma, eg hot thermoplastic material, rapidly into injection mold 1. The halves of die recesses 8a represent and 8b “” cores sll and then molding patterns; for coupling to the corresponding cavities” and then matrices; in the form of the first mold half-cavities 8a “and 8b’ to form a molded plastic part

— 4 3 — has a three-dimensional shape defined by the gap between said mold pattern and said matrix when the injection mold is closed. Comparative example: Swedish engineering consultants 88 Extero conducted tool plate tempering assessments at a third party injection molding plant with molding units and workshop equipment. Measured hardening rates as well as cycle step times were studied and compared to conventional high-pressure injection molding. The results are shown in curves in Figure 5. The rate of tempering of the injection mold given in the present invention for the above curve has an ideal dad of a tempering channel width of about 3.9mm. Significantly, other measurements show that the ideal width varies with the temperature of the oil used. 0 Narrow quenching channels restrict the flow of quenching medium; In the current state oil flow (lower tempering rate); Slightly wider channels improve flow and ventilation rate; While the wide channels form layers with low flow close to the surfaces of the hardening channel (lower hardening rate). The rate of tempering of the injection mold given in the present invention for the above curve increases with the increase in the temperature of the tempering medium; In the current case, the cold oil, i.e. the cooling oil (aay Ba) is better cooling (5 degrees higher oil temperature is given to a lower viscosity and flow lel, and then the decrease in the tempering temperature difference is compensated). The effect on the total hardening rate (temperature change in degrees Celsius per second on the surface of the plasticizing - gia - gia side - from a full-scale tool plate) was studied with different widths (gaps) of the hardening channel Lad relating to: 0 - degrees The variable temperature of a second hardening medium is a mineral quenching oil. - The various temperatures of the first hardening medium are metallic heating oil.

— 5 3 — - various temperature differences between the hot die plate and the mineral cooling oil. Various temperature differences between the cold die plate and the metal heating oil. The test was done with the following plastic materials: ABS - PP - 5 (two different fabrics) POM - In the experiments, the same medium-sized mold had cavities for the following different-sized plastic parts: - A rectangular box (see Figure 4) - A frame with screws (see Figure 4)

0 - Crescent wings (see Fig. 4) - Circular disc For small/medium sized injection molding tools Traditionally injection molding and methods use 0-40 sec cycle time (except for ultra-high volume production solutions). Table 1 below shows cycle time About 25 seconds for a typical medium size injection mold.

For conventional injection molding of the four different plastic parts in experiments, separate injection molds (one for each part) in separate injection molding ATs are required; Each uses 25 sec cycle time to produce one each of these 4 lly plastic parts which then requires a total cycle time of 4 x 25 = 100 sec. The experimental small/medium sized IW of the present invention an actual injection pressure of 9

0 MPa bar for PP molding and 20 MPa for ABS molding where injection molding has traditionally been used

Typically about 90 MPa for PP and about 100 MPa for ABS Molding (sec) Note Step A: Heating (Step C) [15] Not applicable for conventional injection molding methods Cooling 16 16 km Opening was 2 2 Cam Na Pronunciation 2 2 km NA Table 1 For large-format injection molding molds typically the injection molding method and mold is used conventionally 50-100 s cycle time. Table 2 below shows a cycle time of 50 s for a conventional, jumbo-sized mold. However, the cycle time depends strongly on the wall thickness of the plastic gall; Lhe is bigger

— 7 3 — from 2.0mm — which increases rapidly by increasing the wall area of the plastic part to facilitate the injection of the plasticizer. These costly thickness values (a lot of plasticizer) are usually not required for the 'gall lal ¢' function and are only provided to allow conventional molding. In 0/11 the total cycle time for manufacturing a 3.0 mm thick plastic part is 50 sec as the conventional molding time; But at the same time, a significant cost is saved in the plastic material due to the much thinner walls in the plastic part. Does not need

The invention has thick walls to enable the plastic when molding to reach all parts of the molding cavity.

Molding step (secs). NB

0

Heating (step c) is not applied in the conventional instrument

Inspection (step d) is easier to inject plasticizers into a heated cavity

yall 19 3 (| Faster cooling with Al plates and aggressive cooling

(step 4)

Opening 2 3 Movable lighter tool plate and moving parts Jil

(step f

Pronunciation 4 4

(step g)

— 8 3 — Table 2 A summary of the features and advantages of the invention in light of prior art is provided below. Prior art injection molding methods and devices do not suggest the use of very low pressures or no pressures for the plasticizer in the feeds and cavities.

The present invention provides an alternative injection molding method in view of increasing productivity and decreasing manufacturing costs; To compete with low cost manufacturers of injection molded components. The present invention advantageously enables the manufacture of injection molded parts of improved quality and with improved properties in view of the same plastic parts manufactured using conventional injection molding methods and machines and with higher injection pressures. The present invention does not require or urge the removal of at least one or more castings; floating fonts

0 on plastic gall; junction lines in the plastic parts behind the tool cores; and tensile strength in plastic parts. The injection molding machine and method of the present invention utilizes a new injection mold with open channels on the rear side suitable for temperature circulating only one injection molding cavity of all the cavity or the entire injection mold and/or feed channel as well. In this way very low pressure 5 or no pressure prevails in one or more cavities in the injection mold during a molding cycle; That is, there is no high traditional injection molding pressure of plastic feeding. The present invention also enables multiple different parts to be molded into the same injection mould. Due to the circulation and rapid exchange of thermal energy, injection molds can be made of materials with high thermal conductivity that are mechanically more loose and therefore less able to withstand pressure than conventional injection molds 0 steel, for example. The advantage of AT is that mechanically looser materials are machined easier and faster; for example by grinding or cutting; But it is not suitable for casting molds due to the large shrinkage in the sale of metal molds.

Because of the very low pressure in the injection mold during the molding cycle; The pressure that the injection mold can withstand the pressure can be reached without deformation or yield with less thickness of the injection mold material components; This reduces mold material costs and facilitates temperature change; Simply because less material is thermally recycled. The very low injection pressure allows much of the material to be removed from the mold plates; allowing the use of a simple and inexpensive heat exchange arrangement; In light of design and manufacturing. The back side of the die shall have open channel patterns made by mere milling etc.; Without QBN and complex piping configuration. Injection molding plate can be mounted on All cylinders. Injection molding in a simple arrangement (LSS is inexpensive; small, requires low capacity); In the prior art, one or more of the molding recesses shall have the same temperature during injection and cooling.An unusually high temperature in the recesses of the injection mold of the present invention during injection of a plasticizer feed having temperatures in the same range results in a high quality molded shal Likewise, the low temperature in the injection mold cavities during cooling gives a JH cooling time without premature hardening during injection because the cavities are then rapidly cycled to a high temperature again after the resulting plastic part has been extruded The injection molding cycle is from an open injection mould.So the present invention overcomes a prejudice in the injection molding field against too rapid cooling and temperature setting delays in reciprocating temperature adjustment;as in the Variotherm 0 process there is no risk of leakage heat to adjacent areas of the injection mold; Because there are no such adjacent areas when the injection mold is fully heated. Jig complete injection mold heat exchange over a molding cycle through an inexpensive caw system of well-distributed channels; The design is versatile; Its number, location and dimensions can be configured according to the Jie variables, the nature of the feeding with the plastic material and the design of the required plastic part. There is no risk of irregular or local heating/cooling

— 0 4 — only as in the case of the heat exchange being carried out by circulating the fluid in limited areas as in the prior art; or induction elements installed at specific locations of the injection mold. Usable external temperature cycling arrangements are inexpensive (Savy laws) reusing the same arrangement for all cylinder-mounted injection molds. In addition to dll different temperatures can be controlled very precisely from locations outside the injection mold; even from remote locations. Neither the injection molding machine nor the new and innovative injection molding and injection molding method of the present invention presents a challenge to the operator or the mold manufacturer because assembly of various complex mold components is not required; nor dala that the mold maker is trained in the manufacture of integrated hardening channels. no dala for new training in order to design the two halves of an injection mold from an injection mold according to the invention” nor dala 0 for new machines or workshop skills for injection mold making; no dala for new skills for injection molding operations” and all this is required for methods; machines and similar prior art molds that benefit from fluid circulation in limited areas; or the use of induction elements incorporation.An injection mold can be of low weight and can be easily and quickly assembled.Some of the challenges when circulating between heating and cooling the same injection molding tool are: 5 It turns out that heating schemes using pressurized water (eg a pressurized water nuclear plant) are impractical. It is complex and dangerous. Switching between hot oil and cold water is impractical because steam is generated when cold water hits hot parts; It is difficult to control the oil/water mixtures. Separate parallel heat exchange channels for water and oil are ineffective. 9650 of the heat exchange 0 with the tool is on the surface of each of them and the intervention takes place because the water that boils in the water quenching channels is close to the hot oil quenching channels. The cold oil codon flows and has a lower thermal conductivity than water; It forms a boundary layer with very low flow near the surfaces of the hardening channels; It is characterized by a laminar flow parallel to the surface of the quenching channel with almost no oil flowing out of the wall and thus carrying heat away.

— 4 1 —

Cooling an injection molding tool through tempering channels with cold, flowing mineral oil is a compromise

Among many factors; Such as :

small overall size of the tool panels; including the walls between the Adil channels) stores the metal

Heat » The walls of the narrower thermal energy flow path add weight.

Huge heat exchange area.

The huge difference in temperature between the tempering fluid and the die or tool plate.

High thermal conductivity of the ventilation medium.

High flow of the medium for quenching through the channels for quenching.

Swirls and undulations in the flow of the hardening fluid deflect heat away from the walls; Slow 0 flow layer cut near walls; And washing "sticky" oil off the walls.

Huge variation in viscosity with temperature mineral oil (exponential dependency).

Any Lui plastics oa can be injection molded using the new and innovative technology featured in

The present invention is largely without design limitations of molded plastic parts; Because my step

Heating and cooling occur in a very regular manner and largely independent of the locations of one or more cavities in the injection mold.

Claims (5)

Claims 1- A method of molding injection molding plastic parts using a low-pressure injection molding machine, where the method includes the following steps: 0 Providing the injection molding machine with an injection mold that defines a molding cavity molding cavities 5; The injection mold includes an injector mold plate and an ejector mold plate 160101008109; .Where both mold plates have front and back sides where the front side is opposite the back side; and where the back side of the dieplate (cdl) is cut in succession” by one or more open longitudinal channels which are made by milling or cutting the back side of the dieplate concerned which extends between the inlet and outlet of each of them through a free edge of the dieplate concerned; With the provision of a molding cavity / molding cavity molding cavities in the front face and defining the free edge between the front and back sides of the slab (llll) where each channel has its own inlet and outlet and one or more of the longitudinal channels opened at the end are closed first To rotate a hardening medium once the mold sheets are in place in the “injection molding machine” (b) providing feeding with a plastic material having a temperature of Jol within the framework of processing the plastic “material” (x) Heating the molding cavity molding cavities to a second temperature within the framework of curing the plastic material and keeping the injection mold in a closed state at the mentioned second temperature by circulating through the channel or 0 more medium The first tempering having a third temperature; (9) Injecting a plastic material having a first temperature into the closed quenched mold at an injection pressure from 20 to 100 kg/cm2 to fill the molding cavity / molding cavity (8) Cooling the molding cavity Molding cavities of 5 injection mold, packed and closed, to a fourth temperature lower than the first temperature up to — 3 4 — The molded plastic part (shal) within the injection mold is hardened by circulating through the channel(s) a second fifth-temperature quenching medium; (f) opening the injection mold by retracting the mold plate injection mold from the ejector plate “(g) eject the plastic part/(s) before it becomes WS-hardened by operating the ejector pins from the ejector plate” and (h) repeat the cycle of steps (c) - (g) until the desired number of plastic parts has been produced. Optionally, where the fifth temperature is lower than the lowest temperature within the plastic material treatment framework and/or the fourth temperature is lower than the lowest temperature within the plastic material treatment framework 5 3- method according to claim No. 1, whereby in steps (8) and (g) the molded plastic part(s) rt(s) refers to the hardening that makes it easier to pronounce the part(s). 4- A method of claim 1; Cus Step (c) also includes heating a conveyor system feeding the plastic material to a temperature within the plastic material 0 setting at any location prior to the injection mold. 5- A method according to claim No. 1 whereby in step (c) air is emptied from the molding cavity before proceeding to step (d). 56- Method of claim No. 1; Where the plastic material is a sale thermoplastic material. 7- A method according to claim No. 1 (where one or both of the injected plate and the ejector plate are made of aluminum or an aluminum alloy). 8- A method according to claim No. ol since it is in step (d) The plastic material 5 is injected at the first temperature at an injection pressure ranging between 20 kg/cm2 and 80 kg/cm2. PLASTIC MATERIAL 018500 or to 150" m; or 200" m; or 300 2°0 optionally where the first curing medium is oil. 0 - Method of claim No. 1; where the first curing medium and the second curing medium are rotated Through the same open channel(s) or through different channel(s), optionally in response to the opening and closing of the valve(s) associated with each of the inlet(s) of the valve(s). off-center; injector gate(s); or 2-way dla gate(s) of claim 1h where either the first hardening medium or the second hardening medium 0 flows into the channel(s) opened from either the ejector plate or the injector die plate designed as a connected channel having an inlet at one free edge of the respective die plate and an outlet at an opposite free edge; Where the open channel(s) between the inlet and the outlet is a narrow fle that rotates in opposite directions; Where narrow turns are defined by a set of upright walls defining the edges of the canal. 13- lg method for claim number 12) where some existing walls are parallel. 4- A method of claim 1; Where the channel(s) shall be designed to have one or more of the following features: – the turning radius of the channel shank is between 6.0 mm and 30 mm; - the number of channel stems between 3 and 10; - channel leg about 200 mm long; - Total length between 600mm and 8005mm; - depth between 20 mm and 60 mm; - Channel leg widths 3.0mm - 5.0mm; - Channel leg with thickness between 3.5mm and 5.0mm; or 0 - The thickness of the metal goods between the channel and the molding cavity is 3.0mm - 5.5mm. 5- A method of claim 1; Gus The channel(s) (11;14) are designed to have the following features: – a channel leg of about 140 mm long; 5 - five channel legs; - Total length is about 700 mm; - depth between 20 mm and 40 mm; - 4.2mm wide channel leg; - channel leg with a thickness of Ble more than 3.8 mm; or 0 - The thickness of the metal goods between the channel and the molding cavity is 4.0mm. 6- A method according to claim No. 1 in which the second temperature is 20 "C higher than the first Shall degree. 5 17- A method according to Claim No. 1 where the fifth temperature is about 20"C lower than the fourth Shall degree. 8- A method of claim 1; Where the second tempering medium is a mineral oil for it A fifth temperature of 40 "C or less" or 30 "C or less. 9- Low pressure injection molding machine for injection molding for a creditor's part(s) in accordance with Claim 1 method; The injection molding machine includes injection molding machine on: - The is mold includes an injector mold plate and a reciprocating mold plate [molding cavity al ¢ reciprocating ejector mold plate molding cavities in the closed state of an injection mold; where each of the 0 die plates has front and back sides with the front side opposite the back side; And the side is cut off The back of the mold plates are “in series” by open longitudinal channel(s) which are manufactured By milling or cutting the back side of the board concerned and extending between the inlet and outlet of each of them through a free edge of the die plate concerned; The fmolding cavity is provided as a mold cavity molding cavities in the front face and the free edge specified between the front and back sides of the 5-mold board, where each channel has its own entrance and exit, and at the end a channel (channels) is closed The longitudinal open first to circulate the hardening medium once the mold plates are placed in the injection molding AT Cua cinjection molding machine Ducts are designed for the following: during injection at an injection pressure of 20 to 100 kg/m2 of a plasticizing material; where it is at a temperature First within the framework of treating the aforementioned plastic material; Circulation in a molding cavity 0 molding cavities (iss) The first tempering medium has a third temperature From a temperature within the framework of treating the plastic material injected to heat a cavity molding [molding cavity] molding cavities to temperature again; And To harden the molded plastic part(s) inside the injection mold 00014 80000 g GU hardening medium has a fifth temperature selected to cool the molding cavity of 5 molding cavities of a packed, sealed injection mold to temperature a fourth is lower than the first temperature; Heating system to heat a conveyor system to feed the plastic material at any position before Injection mold to a temperature within the framework of processing the plastic material «material Arrangement of a pump to circulate in the circulations of the first tempering medium having a third temperature and the third tempering medium The second that has a fifth temperature through the channel(s) of the injection mold 6f Valve system to control the diversion between the first and second hardening media. all -0 injection molding machine of claim 19; 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